A novel powder-epoxy towpregging line for wind and tidal turbine blades

A novel material and process was developed using fibre-reinforced powder-epoxy to produce unidirectional towpreg with a pilot-scale towpregging line, for cost-effective production of large composite structures for the renewable energy market, specifically for wind and tidal turbine blades. Electrostatic attraction was used to coat fibre tows with powder epoxy and either joule or radiant heating employed to heat and melt the polymer, followed by consolidation between rollers. Unidirectional carbon-fibre and basalt-fibre reinforced polymer laminates (UD-CFRP and UD-BFRP, respectively) were manufactured from the towpreg. Tensile test results showed that the towpregging process could be employed to achieve high performance UD-CFRP with 0° tensile properties that are similar or better than commercially-available UD-CFRP systems. The competitive advantages of the powder-epoxy towpreg system include lower cost, better overall manufacturing control for vacuum-bag-only manufacturing and the ability to co-cure parts together at a later stage. Mechanical test results showed some variation between two types of UD-BFRP, but the results compared well with published data on UD-BFRP and equivalent glass-fibre reinforced polymer (GFRP) systems. Finally, the influence of hygrothermal ageing due to water immersion on the tensile properties of the materials was investigated, with tests revealing that the water ageing effect was more severe in the case of UD-BFRP than for UD-CFRP

Erosion Mapping of Through-Thickness Toughened Powder Epoxy Gradient Glass-Fiber-Reinforced Polymer (GFRP) Plates for Tidal Turbine Blades

Erosion of tidal turbine blades in the marine environment is a major material challenge due to the high thrust and torsional loading at the rotating surfaces, which limits the ability to harness energy from tidal sources. Polymer-matrix composites can exhibit leading-blade edge erosion due to marine flows containing salt and solid particles of sand. Anti-erosion coatings can be used for more ductility at the blade surface, but the discontinuity between the coating and the stiffer composite can be a site of failure. Therefore, it is desirable to have a polymer matrix with a gradient of toughness, with a tougher, more ductile polymer matrix at the blade surface, transitioning gradually to the high stiffness matrix needed to provide high composite mechanical properties. In this study, multiple powder epoxy systems were investigated, and two were selected to manufacture unidirectional glass-fiber-reinforced polymer (UD-GFRP) plates with different epoxy ratios at the surface and interior plies, leading to a toughening gradient within the plate. The gradient plates were then mechanically compared to their standard counterparts. Solid particle erosion testing was carried out at various test conditions and parameters on UD-GFRP specimens in a slurry environment. The experiments performed were based on a model of the UK marine environment for a typical tidal energy farm with respect to the concentration of saltwater and the size of solid particle erodent. The morphologies of the surfaces were examined by SEM. Erosion maps were generated based on the result showing significant differences for materials of different stiffness in such conditions